Reactor and method for maximizing methanol yield by using catalyst layers

Abstract

The invention relates to a reactor for the catalytic production of methanol, in which at least two catalyst layers are arranged. The first catalyst layer is arranged upstream and the second catalyst layer is arranged downstream. The activity of the first catalyst layer is higher than the activity of the second catalyst layer.

The invention claimed is: 
     
       1. Method for the catalytic production of methanol from synthesis gas,
 wherein the method comprises the following steps:
 providing a reactor; 
 arranging at least two catalyst layers for the production of methanol in the reactor, 
 wherein the first catalyst layer is arranged upstream and the second catalyst layer is arranged downstream, and wherein the activity of the first catalyst layer is higher than the activity of the second catalyst layer; 
 applying synthesis gas to the reactor, comprising hydrogen and carbon oxides, 
 converting the synthesis gas in the reactor under methanol synthesis conditions to methanol, 
 channeling the produced methanol and the non-converted synthesis gas out of the reactor. 
 
 
     
     
       2. Method according to  claim 1 , wherein the reactor is a water-cooled reactor and the cooling temperature is between 200° C. and 260° C. 
     
     
       3. Method according to  claim 1 , wherein at least two further catalyst layers for the production of methanol from synthesis gas are arranged in the reactor, wherein the further catalyst layers are each arranged downstream of the second catalyst layer, and wherein the activity of the further catalyst layers successively increases towards the downstream end of the reactor. 
     
     
       4. Method according to  claim 1 , wherein the cooling temperature and the layer thickness and the activity of the individual catalyst layers is chosen such that the resulting reaction temperature in the reactor does not exceed about 260° C. 
     
     
       5. Method according to  claim 2  wherein the cooling temperature is between 230° C. and 250° C. 
     
     
       6. Reactor for the catalytic production of methanol, comprising at least two catalyst layers for the production of methanol arranged in the reactor, wherein the first catalyst layer is arranged upstream and the second catalyst layer is arranged downstream, and wherein the activity of the first catalyst layer for the production of methanol is higher than the activity of the second catalyst layer. 
     
     
       7. Reactor according to  claim 6 , wherein the catalyst layers are arranged directly adjacent to each other. 
     
     
       8. Reactor according to  claim 6 , wherein the catalyst layers are arranged in a single packed bed filling. 
     
     
       9. Reactor according to  claim 6 , wherein the at least two catalyst layers have an essentially identical layer thickness. 
     
     
       10. Reactor according to  claim 6 , wherein further catalyst layers for the production of methanol, are arranged in the reactor, wherein the further catalyst layers are each arranged downstream of the second catalyst layer, and wherein the activity of the further catalyst layers for the production of methanol successively increases towards the downstream end of the reactor. 
     
     
       11. Reactor according to  claim 9 , wherein further catalyst layers for the production of methanol, are arranged in the reactor, wherein the further catalyst layers are each arranged downstream of the second catalyst layer, and wherein the activity of the further catalyst layers for the production of methanol successively increases towards the downstream end of the reactor. 
     
     
       12. Reactor according to  claim 10 , wherein the layer thickness of the first catalyst layer is smaller than the layer thickness of the further catalyst layers. 
     
     
       13. Reactor according to  claim 12 , wherein the layer thickness of the first catalyst layer is 5% to 20% and wherein the further catalyst layers exhibit a substantially identical layer thickness. 
     
     
       14. Reactor according to  claim 13 , wherein a total of four catalyst layers are provided, wherein the layer thickness of the first catalyst layer is 10% of the total thickness of all catalyst layers, and wherein the layer thickness of the three further catalyst layers each is about 30% of the total thickness of all catalyst layers. 
     
     
       15. Reactor according to  claim 10  wherein two further catalyst layers for the production of methanol are provided. 
     
     
       16. Reactor according to  claim 11  wherein two further catalyst layers for the production of methanol are provided. 
     
     
       17. Reactor according to  claim 12  wherein the layer thickness of the first catalyst layer is 10% of the total thickness of all catalyst layers.